Flat ESP Cable Jacket with Asymmetric Splines

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing ESP cables face damage due to distortion or rapid gas decompression during deployment and are difficult to manufacture, especially when subjected to harsh well environments and limited space applications.

Innovation Solution

A flat cable design with asymmetric splines on the jacket layer for protection during armoring and manufacturing, including an orientation spline for phase identification and channels for thermal expansion and stress reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a traditional round cable design is used, then the cable has uniform strength in all directions, but the cable occupies more space and is more difficult to deploy in limited space applications

Engineering Contradiction:

Improvecable cross-sectional areaVSAvoidcable damage resistance

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent applies asymmetry by transitioning from a traditional round cable cross-section to a flat rectangular cross-section with asymmetric reinforcement. The flat profile reduces the vertical dimension for limited space applications, while asymmetric splines and armor layers provide targeted strength where needed during deployment and installation.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The cable is segmented into distinct functional layers including the jacket, splines, and armor layers. This segmentation allows each component to perform its specific function - the jacket provides baseline protection, splines provide edge reinforcement, and armor layers provide mechanical strength - while maintaining an overall compact flat profile.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the cable jacket is made thicker to prevent damage during deployment, then the cable's damage resistance improves, but the cable's operational diameter increases and material usage increases

Engineering Contradiction:

Improvejacket damage resistanceVSAvoidcable operational diameter

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

Instead of uniformly thickening the jacket, the patent applies local quality by adding splines specifically at the minor edges where damage occurs during deployment. This targeted reinforcement provides maximum protection at critical locations while maintaining a thin overall profile and minimizing material usage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The splines act as beforehand cushioning by providing pre-positioned reinforcement at the jacket edges before deployment. These splines absorb and distribute mechanical stresses during installation and deployment, preventing jacket damage without requiring a thicker overall jacket design.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If asymmetric splines are added to the jacket for protection during armoring, then the cable's manufacturing ease improves and damage resistance increases, but the cable's structural complexity increases

Engineering Contradiction:

Improvearmoring process easeVSAvoidjacket structure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The asymmetric splines are incorporated into the jacket during the extrusion process as a preliminary action. This allows the splines to be pre-formed and positioned correctly before the armoring process begins, making the subsequent armoring operation easier and more consistent without requiring complex post-processing steps.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cable design enhances damage resistance, simplifies manufacturing, and reduces the risk of jacket damage during deployment, while maintaining minimal material usage and operational diameter.

Implementation Method 1

The power cables are subjected to harsh working environments containing corrosives, e.g., corrosive gases, elevated temperatures, high pressures

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

Existing ESP cables face damage due to distortion or rapid gas decompression during deployment

Methodology Applied

Scientific EffectFluid absorption and swelling: Absorption (physical)

Data Source

PatentUS11495370B2Thermal expansion and swell compensated jacket for ESP cable

Publication Date: 2022.11.08 SCHLUMBERGER TECH CORP

AI summary

A cable includes insulated conductors arranged in a spaced apart generally coplanar configuration. A jacket encapsulates the insulated conductors. The jacket has a generally rounded rectangular cross-section, at least one spline along a minor edge of the jacket, and at least one channel along a major edge. An armor layer is applied about the jacket.